技术领域technical field
本发明涉及无损检测技术领域，具体涉及一种用于焊缝检测的超声相控阵检测方法。The invention relates to the technical field of non-destructive testing, in particular to an ultrasonic phased array testing method for welding seam testing.
背景技术Background technique
传统超声焊缝检测时，一般需要移动换能器探头才能有效地进行缺陷检查，这要求探头移动区的表面粗糙度要理想；同时，由于入射角度过于垂直，使用波束垂直入射到试块表面时，只能检测到离试块检测面一定距离的缺陷，存在检测盲区。In traditional ultrasonic weld inspection, it is generally necessary to move the transducer probe to effectively detect defects, which requires the surface roughness of the probe moving area to be ideal; at the same time, because the incident angle is too vertical, when the beam is perpendicularly incident on the surface of the test piece , it can only detect defects at a certain distance from the test surface of the test block, and there is a detection blind spot.
现有技术中很少出现针对焊缝缺陷合成孔径成像中信号合成方式的优化，对比文件(201510219036.3)通过基于扫描坐标点的插值权重系数寻找采样点，但对信号获取后的信号合成相关计算并无研究。In the prior art, there are few optimizations for the signal synthesis method in synthetic aperture imaging of weld defects. The comparison document (201510219036.3) finds sampling points by interpolation weight coefficients based on scanning coordinate points, but the correlation calculation of signal synthesis after signal acquisition is not No research.
另外，传统的合成孔径聚焦算法虽然通用性好，但具体运用往往存在瑕疵，比如，运算量较大，成像效果一般，分辨率偏低。In addition, although the traditional synthetic aperture focusing algorithm has good versatility, there are often flaws in its specific application, for example, a large amount of calculation, general imaging effect, and low resolution.
发明内容Contents of the invention
本发明针对传统超声波无损检测存在的问题，提供一种成像质量更好，分辨率更高的超声相控阵检测方法。The invention aims at the problems existing in the traditional ultrasonic nondestructive testing, and provides an ultrasonic phased array testing method with better imaging quality and higher resolution.
本发明的技术方案是，提供一种基于斜入射的超声相控阵焊缝缺陷检测方法，其特征在于：所述焊缝缺陷检测方法包括超声相控阵检测系统和超声相控阵检测步骤，所述超声相控阵检测系统包括超声相控阵信号采集系统、超声相控阵换能器探头、有一定倾斜角度的有机玻璃楔块、连接有机玻璃楔块和试块表面以减少声波散射的水溶剂、连接相控阵超声换能器探头和有机玻璃楔块以减少声波散射的特殊耦合剂及用于计算超声相控阵信号采集系统数据的计算机，所述超声相控阵检测步骤为以下四个步骤：The technical solution of the present invention is to provide an ultrasonic phased array weld defect detection method based on oblique incidence, which is characterized in that: the weld defect detection method includes an ultrasonic phased array detection system and an ultrasonic phased array detection step, The ultrasonic phased array detection system includes an ultrasonic phased array signal acquisition system, an ultrasonic phased array transducer probe, a plexiglass wedge with a certain inclination angle, and a device for connecting the plexiglass wedge and the surface of the test block to reduce sound wave scattering Water solvent, a special couplant for connecting the phased array ultrasonic transducer probe and the plexiglass wedge to reduce sound wave scattering and a computer for calculating the data of the ultrasonic phased array signal acquisition system, the ultrasonic phased array detection steps are as follows Four steps:
(a)根据被检测焊缝试块的尺寸、材料、声波传播速度、焊缝缺陷范围选择合适的超声相控阵检测系统相关参数，该相关参数包含相控阵换能器的孔径大小、探头的频率、超声相控阵阵元宽度及间距、楔块斜楔角、晶片阵元的激发法则；(a) Select the relevant parameters of the ultrasonic phased array detection system according to the size, material, sound wave propagation velocity, and weld defect range of the tested weld test block. The relevant parameters include the aperture size of the phased array transducer, the probe The frequency, the width and spacing of ultrasonic phased array elements, the wedge angle of the wedge, and the excitation law of the chip array elements;
(b)根据超声相控阵系统相关参数确定相控阵探头在试块上放置的位置，激发超声相控阵阵元，通过信号采集系统收集回波信号；(b) Determine the position of the phased array probe on the test block according to the relevant parameters of the ultrasonic phased array system, excite the ultrasonic phased array elements, and collect echo signals through the signal acquisition system;
(c)将收集的回波信号进行A/D转换，然后进行适当延时，再通过计算得到权重系数和累加信号；(c) A/D conversion is performed on the collected echo signal, and then an appropriate delay is performed, and then the weight coefficient and the accumulated signal are obtained through calculation;
(d)将回波信号和权重系数进行信号累加，得到成像图。(d) Accumulate the echo signal and the weight coefficient to obtain the imaging map.
近一步地，在步骤(b)中超声相控阵换能器探头放置在一定角度的斜楔块上，而斜楔块放置在试块表面上。Further, in the step (b), the ultrasonic phased array transducer probe is placed on a wedge at a certain angle, and the wedge is placed on the surface of the test block.
进一步地，步骤(b)中的水溶剂为水，特殊耦合剂为机油、甘油和煤油中的一种Further, the water solvent in step (b) is water, and the special coupling agent is one of machine oil, glycerin and kerosene
更近一步地，在步骤(b)中，采用多阵元合成孔径聚焦法则激励阵元，选用四组阵元同时发射、接收声波，得到回波信号：Furthermore, in step (b), the multi-element synthetic aperture focusing law is used to excite the array elements, and four groups of array elements are selected to simultaneously transmit and receive sound waves to obtain echo signals:
其中S(t)为接收到的阵元信号，N为阵元数目，r为成像点距孔径中心距离，v为声波传播速度，tn可近似表示为xn为发射孔径距孔径中心的距离，θ为成像点与扫面线垂直的平面偏转角。where S(t) is the received array element signal, N is the number of array elements, r is the distance from the imaging point to the center of the aperture, v is the sound wave propagation velocity, tn can be approximately expressed as xn is the distance from the emission aperture to the center of the aperture, and θ is the plane deflection angle of the imaging point perpendicular to the scanning line.
更近一步地，在步骤(c)中，适当延时的整数部分使用采样时间的位移得到，小数部分使用均匀采样的插修值法得到，插值法输出结果为：Furthermore, in step (c), the integer part of the appropriate delay is obtained using the displacement of the sampling time, and the fractional part is obtained using the interpolation value method of uniform sampling. The output of the interpolation method is:
S′[n]＝S[n]+a(S[n+1]-S[n])，S'[n]=S[n]+a(S[n+1]-S[n]),
其中S[n]和S[n+1]都是数字阵列中的数字信号，S′[n]为S[n]和S[n+1]之间的插值信号，系数a为与采样频率有关的数据。Among them, S[n] and S[n+1] are digital signals in the digital array, S'[n] is the interpolation signal between S[n] and S[n+1], and the coefficient a is related to the sampling frequency relevant data.
更近一步地，步骤(c)中的延时信号获得后，权重系数的输出结果为：Further, after the delayed signal in step (c) is obtained, the output result of the weight coefficient is:
其中in
Sdelayed为延时信号，t为时间，为频率响应，j是虚数，k是空间频率指数，i是部分区域线性扫描次数，N是总线性扫描次数，M0为低频范围指数。Sdelayed is a delayed signal, t is time, is the frequency response, j is an imaginary number, k is the spatial frequency index, i is the number of linear scans in some areas, N is the number of total linear scans, and M0 is the index of the low frequency range.
再近一步地，在步骤(d)中，通过计算机对步骤(b)的回波信号和步骤(c)的权重系数进行信号累加并到成像图：Further, in the step (d), the echo signal of the step (b) and the weight coefficient of the step (c) are accumulated by the computer and put into the imaging map:
SW＝ER(t)·SSAFT(t)。SW = ER(t) · SSAFT (t).
本发明的有益效果包括以下几点：The beneficial effects of the present invention include the following points:
1、这种基于斜入射的超声相控阵焊缝检测方法利用有一定倾斜角度的楔块，超声波在接触面发生折射和波型转换，能够更好地检测缺陷，换能器探头小范围移动，就能够检测到试块更深部位，增大了波束覆盖范围，减小了检测盲区；1. This ultrasonic phased array weld inspection method based on oblique incidence uses a wedge with a certain inclination angle, and the ultrasonic waves are refracted and wave-type converted on the contact surface, which can better detect defects, and the transducer probe moves in a small range , it can detect the deeper part of the test block, increase the beam coverage, and reduce the detection blind area;
2、多阵元发射与多阵元接收同时进行的电子扫查功能可以提高检测鲁棒性和分辨率并可明显改善远场区的成像质量；2. The electronic scanning function of multi-element emission and multi-array element reception can improve the detection robustness and resolution and significantly improve the imaging quality of the far field area;
3、传统的合成孔径聚焦技术存在信噪比低、计算量大、旁瓣高、伪像等问题，本发明采用自适应权重加权处理可抑制旁瓣，提高成像分辨率，进一步提高缺陷检出率。3. The traditional synthetic aperture focusing technology has problems such as low signal-to-noise ratio, large amount of calculation, high side lobes, and artifacts. The present invention adopts adaptive weight weighting processing to suppress side lobes, improve imaging resolution, and further improve defect detection Rate.
附图说明Description of drawings
为了更清楚地说明本发明实施例中的技术方案，下面将对实施例描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings that need to be used in the description of the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present invention. For those skilled in the art, other drawings can also be obtained based on these drawings without creative effort.
图1是本发明实施例的超声相控阵结构示意图；Fig. 1 is the structural schematic diagram of the ultrasonic phased array of the embodiment of the present invention;
图2是本发明实施例的焊缝缺陷试块的结构图；Fig. 2 is the structural diagram of the weld defect test block of the embodiment of the present invention;
图3是本发明实施例的斜入射超声相控阵焊缝缺陷优化成像图。Fig. 3 is an optimized imaging diagram of oblique incident ultrasonic phased array weld defects according to an embodiment of the present invention.
具体实施方式detailed description
下面结合附图和具体实施例对本发明作进一步说明。The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.
本发明提供一种基于斜入射的超声相控阵焊缝缺陷检测方法，结构示意图如图1，所述超声相控阵包括超声相控阵信号采集系统、相控阵超声换能器探头、有一定倾斜角度的有机玻璃楔块、连接有机玻璃楔块和试块表面的水溶剂、连接相控阵超声换能器探头和有机玻璃楔块的特殊耦合剂及用于计算超声相控阵信号采集系统数据的软件；具体实施步骤如下：The present invention provides an ultrasonic phased array weld defect detection method based on oblique incidence. The schematic diagram of the structure is shown in Figure 1. A plexiglass wedge with a certain inclination angle, a water solvent connecting the plexiglass wedge and the surface of the test block, a special couplant for connecting the phased array ultrasonic transducer probe and the plexiglass wedge, and used to calculate the ultrasonic phased array signal acquisition System data software; specific implementation steps are as follows:
(a)选取一块长高宽为300*300*20mm的普通碳素钢钢板作为试块。在该碳素钢钢板中，声波横波速度约为3200m/s，纵波速度为5900m/s，碳素钢钢板的缺陷图如图2，超声波换能器探头选择的是一枚型号为5L64的超声探头；(a) Select an ordinary carbon steel plate with a length, height and width of 300*300*20mm as a test piece. In the carbon steel plate, the shear wave velocity of the sound wave is about 3200m/s, and the longitudinal wave velocity is 5900m/s. The defect map of the carbon steel plate is shown in Figure 2. The ultrasonic transducer probe is a 5L64 probe;
(b)根据缺陷范围，确定超声波检测参数：探头孔径为38.4mm、换能器探头的中心频率为5MHz、阵元间距为0.6mm、楔块的倾斜角度为54°、采样频率为100MHz；(b) Determine the ultrasonic detection parameters according to the defect range: the probe aperture is 38.4mm, the center frequency of the transducer probe is 5MHz, the array element spacing is 0.6mm, the wedge angle is 54°, and the sampling frequency is 100MHz;
(c)在利用相控阵电子扫查功能对焊缝缺陷进行检测前，先在楔块上涂抹特殊甘油制成的耦合剂，然后把换能器探头与楔块连接、紧固；碳素钢钢板表面均匀撒上水使得碳素钢钢板待检部位表面湿润，然后将探头放在被水湿润的碳素钢钢板块上面，使探头处在缺陷上方；(c) Before using the phased array electronic scanning function to detect weld defects, first apply a coupling agent made of special glycerin on the wedge, and then connect and fasten the transducer probe to the wedge; Sprinkle water evenly on the surface of the steel plate to make the surface of the carbon steel plate to be inspected wet, and then place the probe on the wet carbon steel plate so that the probe is above the defect;
(d)对焊缝缺陷碳素钢钢板进行超声检测，对获得的回波信号进行A/D转换，然后进行适当延时，进而得到权重系数，通过计算机对得到的权重系数和之前获得的回波信号进行累加并获得成像图。由图3可以看出横向和纵向方面的分辨率较高，成像效果较好。(d) Carry out ultrasonic testing on the carbon steel plate with weld defects, perform A/D conversion on the obtained echo signal, and then perform appropriate delay to obtain the weight coefficient, and use the computer to compare the obtained weight coefficient with the previously obtained echo signal Wave signals are accumulated and an imaging map is obtained. It can be seen from Figure 3 that the horizontal and vertical resolutions are higher, and the imaging effect is better.
以上所述仅是本发明的优选实施方式，本发明的保护范围并不仅局限于上述实施例，凡属于本发明思路下的技术方案均属于本发明的保护范围。应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理前提下的若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。The above descriptions are only preferred implementations of the present invention, and the protection scope of the present invention is not limited to the above-mentioned embodiments, and all technical solutions under the idea of the present invention belong to the protection scope of the present invention. It should be pointed out that for those skilled in the art, some improvements and modifications without departing from the principles of the present invention should also be regarded as the protection scope of the present invention.
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| CN201710573490.8ACN107356670A (en) | 2017-07-14 | 2017-07-14 | A kind of ultrasonic phase array weld defect detection method based on oblique incidence |
| Application Number | Priority Date | Filing Date | Title |
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| CN201710573490.8ACN107356670A (en) | 2017-07-14 | 2017-07-14 | A kind of ultrasonic phase array weld defect detection method based on oblique incidence |
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| CN107356670Atrue CN107356670A (en) | 2017-11-17 |
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| CN201710573490.8APendingCN107356670A (en) | 2017-07-14 | 2017-07-14 | A kind of ultrasonic phase array weld defect detection method based on oblique incidence |
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| RJ01 | Rejection of invention patent application after publication | Application publication date:20171117 |